Battery module housing to which electromagnetic pulse bonding technology is applied and method for manufacturing same

Abstract

A battery module housing having a rectangular tube structure and method for forming the battery module housing is provided. The battery module housing includes a first side plate and a second side plate, the first and second side plates having target portions at upper and lower ends thereof, respectively, and spacers vertically protruding from the target portions; and a top plate and a bottom plate disposed upper and lower portions of the first and second side plates, respectively, each of the top and bottom plates having flyer portions supported on the spacers of the first and second side plates. The flyer portions of the top and bottom plates are joined to the target portions by means of electromagnetic pulse welding such that outer portions of the flyer portions contact the target portions and inner portions of the flyer portions are separated from the target portions by a gap.

What is claimed is: 
     
       1. A battery module housing having a rectangular tube structure in which an inner space for accommodating battery cells is formed, the battery module housing comprising:
 a first side plate and a second side plate disposed upright to face each other, the first side plate and the second side plate having target portions provided at an upper end and a lower end thereof, respectively, and spacers vertically protruding from the target portions; and 
 a top plate and a bottom plate disposed horizontally at an upper portion and a lower portion of the first side plate and the second side plate, respectively, each of the top plate and the bottom plate having flyer portions supported on respective spacers of the first side plate and the second side plate, 
 wherein the flyer portions of the top plate and the bottom plate are welded to respective target portions of the first and second side plates by means of electromagnetic pulse (EMP) welding such that outer portions of the flyer portions contact the respective target portions and inner portions of the flyer portions are separated from the respective target portions by a gap. 
 
     
     
       2. The battery module housing according to  claim 1 ,
 wherein the flyer portions are provided at opposite ends of the top plate and the bottom plate, and 
 wherein each of the top plate and the bottom plate includes a cover portion formed between respective flyer portions, each of the cover portions has a greater thickness than the respective flyer portions, and each of the cover portions is fitted into a space between the respective spacer of the first side plate and the respective spacer of the second side plate to be positioned with respect to the first side plate and the second side plate. 
 
     
     
       3. The battery module housing according to  claim 2 ,
 wherein a step is formed between each of the flyer portions and the cover portion of the top plate and the bottom plate, and 
 wherein each spacer has a rectangular cross section to be in surface contact with respective stepped surfaces of the top plate and the bottom plate. 
 
     
     
       4. The battery module housing according to  claim 2 ,
 wherein a first side portion of each spacer, which is oriented toward the inner space, has a round structure and is in contact with the respective cover portion. 
 
     
     
       5. The battery module housing according to  claim 4 ,
 wherein a second side portion of the spacer, which is opposite to the first side portion, has a chamfer structure. 
 
     
     
       6. The battery module housing according to  claim 1 ,
 wherein each flyer portion includes:
 a non-welded region, which extends beyond an end of the target portion before the EMP welding is performed, and thus is not welded with the target portion, and 
 a notch located adjacent the end of the target portion, the notch being configured to cause the non-welded region to be cut off due to an impact when the EMP welding is performed. 
 
 
     
     
       7. The battery module housing according to  claim 1 ,
 wherein each spacer is provided at a side edge of the target portion that is closest to the inner space. 
 
     
     
       8. A method for manufacturing a battery module housing having a rectangular tube structure in which an inner space for accommodating battery cells is formed, the method comprising:
 a preparation step of providing a first side plate, a second side plate, a top plate and a bottom plate, each of the first side plate and the second side plate having target portions provided at an upper end and a lower end thereof, respectively, when the first side plate and the second side plate are upright, and spacers vertically protruding from the target portions, and each of the top plate and the bottom plate having flyer portions formed at opposite ends thereof; 
 a positioning step in which the first side plate and the second side plate are disposed upright to face each other, and the top plate and the bottom plate are disposed horizontally at an upper portion and a lower portion of the first side plate and the second side plate, respectively, such that the flyer portions of the top plate and bottom plate are supported by the spacers of the first side plate and the second side plate to define a gap between the target portions and the flyer portions while facing the target portions; and 
 an electromagnetic pulse (EMP) welding step of welding the flyer portions to the target portions by means of an electromagnetic force formed by an induced current at the flyer portions such that a portion of the gap remains between the target portions and the flyer portions. 
 
     
     
       9. The method for manufacturing a battery module housing according to  claim 8 ,
 wherein each of the top plate and the bottom plate includes a cover portion formed between respective flyer portions, and each of the cover portions has a greater thickness than the respective flyer portions, and 
 wherein in the positioning step, the cover portion is fitted into a space between the respective spacer of the first side plate and the respective spacer of the second side plate to be positioned with respect to the first side plate and the second side plate. 
 
     
     
       10. The method for manufacturing a battery module housing according to  claim 9 ,
 wherein a step is formed between each of the flyer portions and the cover portion of the top plate and the bottom plate, and 
 wherein each spacer has a rectangular cross section to be in surface contact with respective stepped surfaces of the top plate and the bottom plate. 
 
     
     
       11. The method for manufacturing a battery module housing according to  claim 9 ,
 wherein a first side portion of each spacer, which is oriented toward the inner space, has a round structure and is in contact with the respective cover portion. 
 
     
     
       12. The method for manufacturing a battery module housing according to  claim 11 ,
 wherein a second side portion of the spacer, which is opposite to the first side portion, has a chamfer structure. 
 
     
     
       13. The method for manufacturing a battery module housing according to  claim 8 ,
 wherein each flyer portion includes a non-welded region, which extends beyond an end of the target portion before the EMP welding step is performed, and thus is not welded with the target portion during the EMP welding step. 
 
     
     
       14. The method for manufacturing a battery module housing according to  claim 13 ,
 wherein each flyer portion includes a notch adjacent the end of the target portion, and 
 wherein the non-welded region is cut off due to an impact when the EMP welding step is performed. 
 
     
     
       15. The method for manufacturing a battery module housing according to  claim 8 ,
 wherein each spacer is provided at a side edge of the target portion that is closest to the inner space.